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FLSmidth Laboratory Automation Solution

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FLSmidth, an important cement industry equipment and service provider, has its own version of a robotic laboratory. The facility helps to control cement quality and fully meets industry standards for reliability and robustness in an industrial environment.

Cement plants are facing increasingly tough requirements for sample analysis quality and complexity, and for sample throughput. This is partly a result of environmental regulations placing stricter controls on cement production, both in terms of pollution and energy consumption.

In addition, the current economic climate demands 24/7/365 cement plant operation, with as little manpower as possible, with increased productivity.

Many cement plants are in areas where it is difficult to recruit skilled engineers, and people who are available often spend less time in the same job. Remote operation, support from distant locations, and online assistance are all vital for the smooth operation of quality control systems in modern cement plants. The trend in cement plant quality control systems is to meet the following requirements:
Improve the speed and accuracy of sample results;
Meet the stricter controls required for the cement market;
Support 24/7/365 operations;
Achieve zero health and safety incidents.

Supporting product quality control at all stages
The QCX? system from FLSmidth is designed to control cement quality in cement plants and it fully meets industry standards for reliability and robustness in an industrial environment. Automated sampling, sample preparation and analysis provide fast, reliable and consistent information for quality and process control.

The system supports quality control at all relevant stages of cement production in a single, integrated system. Combined with FLSmidth’s extensive experience in cement plant process control, the system incorporates in-depth understanding of production environments and the high requirements for speed and performance. The modular system architecture allows for any degree of automation.

It can be scaled from small task-targeted automation units to large, fully automated laboratories.

KPI for the Quality Laboratory

  • Cost-effective production with high quality;
  • Strict documentation requirements;
  • Continuous plant operation.

Cost-effective production with high quality
Cement production requires fast and correct results to improve quality and reduce operational costs. The Laboratory Automation System transports the samples from the plant to the laboratory; the samples travel 1,500 metres in seconds. The Centaurus, Combined Mill and Press prepare the sample for XRF analysis. The entire process of sampling, preparation and analysis of various equipment like XRF, Free Lime Analysis and Blaine analysis can be done together in the automated laboratory in a foolproof system.

Strict documentation requirements
Stricter QC and audit trail requirements are part of the daily operation of cement plants. The QCX system supports unmanned documented handling of material from process to analysis, avoiding introducing human errors.

Continuous plant operation
For 24/7 plant operation, the process laboratory must operate constantly with only very few, short stops. This means that efficient maintenance and service of all equipment is crucial. To support 24/7 plant operation, the QCX system monitors key components’ KPIs, enabling verification of run hours and end of lifetime for wear parts facilitating spare-part sourcing and reducing downtime for maintenance is part of FLSmidth ‘s global support organisation for fast and easy remote troubleshooting.

A solution for every need
FLSmidth’s comprehensive equipment portfolio, designed specifically for cement production laboratories, ranges from manual machines and automated units to fully automated, high-capacity laboratories. By design, most of FLSmidth’s laboratory equipment is semi-automated and can also be operated manually, as standalone equipment. This means you have the advantage of implementing stepwise automation and of ensuring operation, even when part of the automated laboratory is being serviced.

The QCX system ensures that your process laboratory delivers safe, efficient and accurate analysis quickly and with as few operators as possible. The advanced, user-friendly system can be tailored according to your specific cement production needs, including special cement and fuels, and supports 24/7/365 operation. More than 40 years of development across multiple hardware platforms and a comprehensive base of installed systems has made the QCX system the frontrunner in the cement industry. Automated laboratory solutions from FLSmidth are setting new industrial standards in terms of ease of use, flexibility, reliability and scalability.

Inconsistency in sampling
Sampling inconsistency and inaccurate analysis results contribute to laboratory errors, creating process fluctuations and disrupting productivity, equipment lifetime and especially product quality.

Sampling is the critical first step in the quality control chain. Without correct sampling, preparation and analysis are only a lottery. Balancing your cement plant’s chemistry can be challenging. Sampling inconsistency and inaccurate analysis results contribute to laboratory errors. These errors create process fluctuations and disrupt productivity, reducing equipment life while jeopardizing product quality. According to ‘Sample Theory Studies’, the quality errors come from: Sampling (86.5 per cent); preparation (9 per cent) and analysis (4.5 per cent).

Accurate, automatic sample analysis assists you to take control of your cement plant’s chemistry, its performance and the quality of its output.

QCX/AutoSampling V8 from FLSmidth controls automatic sampling and pneumatic transport of sampled material from the process areas to the production laboratory, and it remains unmatched in its software functionality and performance.

Automated sampling results in samples being taken at the right time, at the right place and consistently. It’s a safe choice. It also:

  • Ensures sampling quality remains high and samples are representative of the larger production;
  • Allows for fail-safe sample identification, including timestamp;
  • Minimises sample-to-sample cross contamination;
  • Provides automated composite/average sampling.

Automated sampling combined with automatic transportation results in:

  • Fast turnaround times from sampling to analysis;
  • Full sample traceability – where and when was this sample taken;
  • Improved quality control;
  • Optimised overall sample-taking schedule;
  • Flexible operator call for additional samples;
  • High system availability;
  • Easy connectivity to automatic sample preparation systems;
  • No health and safety issues as no humans are needed for sample taking;
  • Less labour requirements, allowing the workforce to undertake other important tasks;
  • Improved and fast troubleshooting and maintenance through informative faceplates describing all information from the samplers and sending stations;
  • Tube transport systems have been employed for fast sample transportation in harsh industrial environments since the 1960s. FLSmidth has been involved since the early days and has gained a market-leading position within this technology through execution of hundreds of projects with automated sampling and sample transportation to customers worldwide;
  • QCX/AutoSampling provides automatic sampling and pneumatic transport of sampled material from the process areas to a central production laboratory or to designated ‘satellite’ laboratories;
  • Manual, semi-automatic, or fully automated send/receive stations are available both at the process end and at the laboratory end of a pneumatic sample transport system. Sampling equipment for powder, granulate or and lumpy materials can be connected to the process send/receive stations, thereby ensuring fully automated procedures;
  • Samples are transported in sample cartridges (or carriers or shuttles). For dry powder/granulates, typically 200-500 cc material is sent to the laboratory;
  • The applied advanced logic control programming techniques (oQCXSYSo) ensures cost-effective engineering for the specific project as well as providing a very high quality and consistency in both overall and device control. Directly from the PC screen, mimic diagrams (so-called ‘face-plates’) provide easy accessible operational and diagnostic details from the device control level.
  • Samples are sent from the process stations to receive/send stations in the laboratory in accordance with individual sample priorities and wait list status. Sample entities like sampling location, product type, sampling time, etc., are automatically passed on to the next handling stage, whether manual or automatic. The integrated automation concept includes advanced priority handling schemes: in case an equipment error leads to reduced capacity in the automated preparation system, it is possible to automatically scale down the automatic sampling & sample transport activity, so that lower priority samples are skipped or called for less frequently;
  • Automatic sample transport complements automatic sampling and creates fully automated sampling procedures;
  • Fast turnaround time from sampling to analysisl;
  • Improved product quality and related operational savings;
  • Optimised overall sample taking schedule;
  • High system availability;
  • Easy connectivity to automatic sample preparation systems;
  • Worldwide service & support.

Sampling made easy
QCX/AutoSampling V8 can be seamlessly configured to suit your work processes. FLSmidth has semi- and fully-automated samplers for all cement plant applications – from raw material to cement dispatch including a new hot kiln outlet sampler that enables very fast clinker analysis, and thereby fast feedback to chemical changes introduced in the kiln. With its intuitive user interfaces, and informative faceplates, the system provides a complete overview of all sampling issues directly at the laboratory. Most importantly, it delivers reliable samples!

FLSmidth has more than 200 QCX/AutoSampling systems installed worldwide. Fast and accurate sample preparation and analysis results in greater quality control. It sets your production capabilities apart from the rest.

FLSmidth QCX Robolab
FLSmidth’s QCX/RoboLab aims to simplify some of those complexities. The single, integrated QCX/RoboLab system uses leading-edge technology to deliver automated sampling, sample pre?paration and analysis that’s fast and reliable, and provides consistent information for quality and process control at all stages of cement production.

QCX/RoboLab V8 – improved quality, reduced variance
QCX/RoboLab reduces the hard, repetitive and sometimes hazardous work in the laboratory, to reduce human errors, and to ensure safe, fast, reliable and accurate analysis. It is instrumental in achieving optimum performance.

A QCX/RoboLab system consists of semi-automated sample preparation equipment, sample manipulators, such as a robot or conveyers and manipulators, and state-of-the-art software to handle both the automation and the sample control and laboratory information management system (LIMS) functionalities.

QCX/RoboLab allows for varying degrees of automation. It can be scaled from small, task-targeted automation units to large, fully automated laboratories. Installations have ranged from systems with one robot, one sample preparation machine and one analyser to systems with eight robots and numerous other equipment.

All-in-one combined mill & press
The only all-in-one automated solution that can grind and press or just grind or just press.

FLSmidth’s ‘Centaurus’ automatic sample preparation machine combines laboratory mill and press functions in a compact, easy-to-operate unit. Centaurus consists of an automatic fine grinding mill and an automatic pelletising press. The components for both these main functionalities are integrated in a space-saving and ergonomically designed (award-winning) housing with a footprint of only 1 m2.

The fully automatic Centaurus produces pressed powder test tablets from granular materials such as raw meal, clinker, cement, ore, slag and mine exploration samples for XRF and XRD analysis. Automated quality control systems help improve the product quality in industrial processes. FLSmidth has taken product quality one step further with the unique Centaurus sample preparation machine.

Functionality
The Centaurus houses a sample dosing device, an automatic fine-grinding mill and an automatic pelletising press in a soundproof 1m2 unit. It fits seamlessly into new or existing production laboratory set-ups.

Designed to function as a standalone system or to be integrated with linear or robotics automation systems, the Centaurus has two different operation sides – a human and an automatic side, which allows a smoothly integration into FLSmidth’s QCX/RoboLab system, as well as the use as a standalone machine, because the Centaurus supports automatic feed of samples directly to any X-ray analyser.

The unique thing about Centaurus is its ability to grind sample material without pressing it, or to press sample material without grinding it.

The ‘grinding only’ feature is a standard functionality, while the ‘pressing only’ feature is an available option. Before the grinding and pressing stage, the sample material type is identified from the operator terminal, or via the interface of a supervisory quality control system such as the QCX system.

The preparation method and associated parameters are then selected and the fully automatic sample preparation process begins:
In the flagship of fully-automated sample processing, QCX/RoboLab, the Centaurus plays the main role in sample preparation.

Arriving in the automatic receiving station and filled in the cups, the robot transfers the sample to the Centaurus where the fully automatic sample preparation cycle starts.

From the output position the pressed tablet is placed on the belt leading to the X-ray machine.

QCX/Blend Expert V8
FLSmidth has more than 700 QCX/Blend Expert applications installed worldwide. With QCX/Blend Expert, the complex task of controlling varying raw materials is no longer manual. Its tight control of raw material blending reduces fuel consumption in the kiln, and it delivers kiln feed quality out of the mill, eliminating the need for well working blending silos.

Easy to install, easier to use
FLSmidth has combined more than 40 years of experience in material proportioning in the development of QCX/BlendExpert V8. The software offers significant improvements for all cement plants.

It has been designed using the latest control technologies and can be installed on a standard PC, physical or virtual, standalone or on top of another QCX system. It has an easy-to-interpret graphical interface and advanced alarm and trend capabilities.

For further details, contact: S. Sankaralingam
(Ph. +91 7358058894); Altrin Prabahar. S.
(Ph.+91 7358046923), FLSmidth Ltd.

Maximum efficiency, higher productivity
QCX/BlendExpert provides cement plants with a competitive edge and allows plant owners and managers to achieve what other plants without advanced quality control systems can’t achieve.

  • Up to 60% lower standard deviation of quality targets.
  • Fast payback of system investment
  • due to:
  • Lower fuel consumption in the kiln and pre-heater;
  • Reduced equipment wear and longer lifetime of mechanical parts – less thermal stress is a direct benefit of QCX/BlendExpert’s stable burning.
  • Reduced need for blending silos.
  • Higher kiln alternative fuel substitution rate.
  • Steady 24/7/365 control philosophy.
  • Intuitive user interface, providing easy overview of ‘next step’ process control.
  • Fast troubleshooting of material feeders through direct monitoring of feeder operation.
  • Improved accuracy and benefits of online analysers through dynamic bias correction and automated handling.
  • Optimal use of raw materials and additives, leading to cost savings.
  • Optimal control of material blending during upset conditions – no need to switch to manual control.

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Economy & Market

RAHSTA Roundtable Sets Agenda for Smarter, Safer Highways

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Roundtable discussions focus on innovation for safer highways.

Held on 12 March 2026 at Courtyard by Marriott, Mumbai, alongside the Infrastructure Today Airport Conclave, the RAHSTA Roundtable brought together stakeholders from across the highways and infrastructure ecosystem to shape the agenda for the 16th RAHSTA 2026, scheduled for 8–9 July 2026 at the Jio Convention Centre, Mumbai. The session focused on key industry themes including road construction, technology, safety and long-term sustainability.

Opening the discussion, Pratap Padode, Founder, FIRST Construction Council, said the roundtable marked the beginning of a broader consultative process leading up to the July event. The aim, he noted, is to bring together industry stakeholders to refine the agenda for discussions on the future of roads, bridges, tunnels and allied infrastructure.

Padode noted that while central road project awards have slowed in recent years, states are increasingly driving the next phase of infrastructure growth. Maharashtra, with its long-term road development plans and agencies such as MSRDC and MSIDC, is expected to play a significant role in this expansion.

RAHSTA Expo 2026 as a specialised platform dedicated to road infrastructure, covering highways, tunnels, bridges and flyovers along with construction technologies, safety systems and maintenance solutions. He also highlighted the growing importance of rural connectivity and said the organisers are engaging with government bodies to highlight rural road development initiatives.

Tanveer Padode, CIO, ASAPP Info Group, presented insights from IMPACCT, the group’s infrastructure intelligence platform. He pointed to a strong project pipeline despite slower highway awards earlier in the year, noting that states such as Maharashtra, Odisha and Arunachal Pradesh are emerging as key drivers of new projects. The data also revealed that only a small group of contractors participates in large-value infrastructure bids.

Lt Gen Rajeev Chaudhary, former Director General, Border Roads Organisation and Chairman of the RAHSTA Expo Committee, emphasised the need for stronger collaboration across the ecosystem, including policymakers, contractors, technology providers and financiers. He also called for addressing systemic issues within the sector and encouraged greater participation of women in infrastructure leadership.

The discussion also explored the evolving economics of road development. Phani Prasad Mandalaparthy, Associate Director, CRISIL Intelligence, noted that the slowdown in project awards reflects a shift towards higher-value logistics corridors rather than simple road widening projects. However, private participation through BOT and TOT models remains limited.

From the contractors’ perspective, Sudhir Hoshing, Whole-Time Director, Ceigall, said companies are becoming more selective in bidding, favouring projects with clearer payment mechanisms and efficient processes. While NHAI continues to offer greater operational clarity, states such as Uttar Pradesh and Bihar were cited as relatively supportive environments for project execution.

Durability and sustainability also emerged as key themes. Himanshu Agarwal, COO – Road & Infrastructure, Zydex Group India, highlighted the need to prioritise lifecycle performance and resilient pavements, while participants discussed the potential of alternative materials such as plastic waste, steel slag and industrial by-products in road construction.

Dr LR Manjunatha, Vice President, JSW Cement, emphasised that India has abundant fly ash, slag and other industrial materials that can improve durability and sustainability if integrated into specifications and policy frameworks.

Technology and equipment challenges were also discussed. Dr Lakshmana Rao Mantri, Dy General Manager, Afcons Infrastructure, highlighted the shortage of tunnel boring machines (TBMs), which is delaying several underground infrastructure projects. Participants agreed that developing domestic TBM manufacturing capabilities will be critical for future infrastructure expansion.

The future of concrete pavements was another area of discussion. Dr V Ramachandra, President, Indian Concrete Institute, stressed that the debate should focus on lifecycle performance rather than material choice alone, noting that evolving design standards are improving the feasibility of concrete roads.

Prof Dharamveer Singh of IIT Bombay added that while India has made significant progress in infrastructure development, stronger capacity building and better execution practices are essential to ensure consistent road quality.

The discussion also touched upon technology adoption in the sector. Rushabh Mamania, Partner & CBO, Roadvision, highlighted the growing role of AI in road infrastructure, noting that AI-driven monitoring systems are already being deployed across large stretches of national highways.

Overall, the roundtable underscored that the future of highway infrastructure will depend not only on the pace of construction but also on durability, safety, technology integration and sustainable materials. The discussions offered valuable insights that will help shape the agenda for RAHSTA 2026 and guide future collaboration within the industry.

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Economy & Market

CTS Roundtable Charts Tech-Led Roadmap for Construction

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CTS Roundtable Maps Technology Roadmap for Construction

Ahead of the Construction Technology Show (Con Tech Show) 2026, industry leaders, technology innovators and academia came together in Mumbai to deliberate on how digitalisation, automation and industrialised construction can reshape the sector. The discussion made one thing clear: construction can no longer afford to treat technology as optional.

Held on 12 March 2026 at Courtyard by Marriott, Mumbai, alongside the Infrastructure Today Airport Conclave, the CTS Roundtable served as a precursor to the Construction Technology Show 2026, scheduled for 19–20 August 2026 at NESCO, Mumbai.

A platform to move from discussion to deployment

Opening the session, Pratap Padode, Founder and Editor-in-Chief, ASAPP Info Global Group, said construction technology has long remained close to his heart, especially given the sector’s traditionally slow pace of technology adoption. He noted that over the years, the Construction Technology Summit had steadily built interest, and the next step was now to expand it into a larger, more meaningful platform that could bring together technology providers, users, startups and innovators under one roof.

Padode said the vision for CTS is not limited to software alone. The platform aims to embrace all forms of technology that can improve construction efficiency, quality and execution—from digital tools and project management systems to lean construction, off-site fabrication and startup-led innovation. He also highlighted plans to deepen startup participation and create space for young companies to showcase emerging construction solutions.

Industry at a turning point

Moderating the roundtable, Naushad Panjwani, Chairman, Mandarus Partners, set the context by pointing out that the global construction industry, despite being a multi-trillion-dollar sector, continues to lag in productivity. He noted that while manufacturing has consistently improved efficiency, construction has remained slow to modernise.

Referring to both global and Indian trends, Panjwani underlined that the industry is now at a decisive moment. India, he said, is entering a major build cycle, and delivering the next phase of infrastructure and real estate growth through traditional methods alone is no longer viable. The goal of the roundtable, therefore, was not to debate technology in isolation, but to identify the most critical conversations that would bridge the gap between innovation and implementation.

His central message was clear: CTS 2026 must be shaped around themes that make CEOs, CIOs and CTOs feel they cannot afford to miss the event.

From BIM to AI, data to governance

A major theme that emerged through the discussion was the need for better data, better visibility and better decision-making. Dr Venkata Santosh Kumar of IIT Bombay echoed this, saying that the underlying data infrastructure itself needs attention. Construction projects, particularly remote ones, often face issues around connectivity, data collection and data use. Without this foundation, more advanced technologies cannot deliver their full value.

Chandra Vasireddy, CEO & Co-founder, Inncircles, expanded the discussion to governance, arguing that technology must help connect the many moving parts of a construction business. For him, the real value of digital transformation lies in creating better governance, clearer visibility and stronger business outcomes.

Tejas Vara of Inncircles stressed the importance of timely site data for leadership teams, especially in large and remote projects where decisions on materials, machinery and manpower often get delayed because information does not reach headquarters in time.

The role of AI also featured prominently. Rushabh Mamania, Partner and CBO, Roadvision said that while AI and machine learning are now common terms, vision intelligence and language intelligence have still not deeply penetrated the construction sector. He emphasised that startups in India are building relevant AI-led solutions and are already attracting international interest, showing that innovation need not be imported—it can be built locally and scaled globally.

Industrialised construction gains ground

The roundtable also placed strong emphasis on industrialised construction methods. Kalyan Vaidyanathan, CTO – Construction & R&D, Tvasta, called for greater focus on off-site fabrication and the broader industrialisation of construction. Bhargav Jog, General Manager, Dextra, highlighted precast technology and alternative sustainable materials as areas with immediate relevance.

Several participants agreed that modular, precast and pre-engineered approaches are no longer niche ideas. They are increasingly becoming practical responses to the sector’s challenges around labour shortage, timelines, quality control and predictability.

Anup Mathew, Sr VP & Business Head, Godrej, argued that the industry needs a fully integrated approach—from design and procurement to execution and asset management. Unless these are connected, technology adoption will remain fragmented and sub-optimal. He pointed to pre-engineered and modular systems as examples of how industrial thinking can compress timelines, improve quality and reduce dependence on difficult on-site conditions.

Adoption remains the biggest hurdle

While there was broad agreement on the promise of technology, the discussion repeatedly returned to one fundamental challenge: adoption.

Abhishek Kumar, COO, LivSYT, observed that the market is crowded with solutions, but many buyers still struggle to evaluate which technology suits which use case. According to him, the industry needs clearer frameworks to help users select, compare and adopt solutions, rather than expecting a single platform to solve every problem.

Dr Tenepalli JaiSai, Associate Professor, School of Construction(SoC), NICMAR University, noted that isolated technologies will not solve the productivity problem by themselves. What is required is an integrated Construction 4.0 approach, where digital, physical and cyber-physical systems work together rather than in silos.

That concern around silos was reinforced by Subodh Dixit, former Director, Shapoorji Pallonji, who said the issue is not just that technologies are disconnected, but that stakeholders are as well. Clients, consultants, contractors and partners often operate with different priorities. Unless these silos are broken, technology will struggle to percolate across the full project value chain.

Harleen Oberoi, Project Management, Tata Realty shared a practical perspective from the client side, saying that successful BIM implementation requires investment across the ecosystem, not just within one organisation. Trade partners, vendors and other stakeholders must also be trained and aligned if the technology is to deliver its intended results.

Beyond buzzwords

A notable takeaway from the session was that the industry is moving past the phase of treating technology as a buzzword. Participants repeatedly stressed that the real question is not whether technology should be used, but where it creates measurable value and how that value can be scaled.

The conversation also expanded beyond mainstream themes to include repairs and rehabilitation, construction and demolition waste, sustainability, circular economy, green sourcing, carbon measurement, design interoperability, generative design, robotics, and the role of horticulture and greener built environments.

Setting the agenda for CTS 2026

By the close of the session, the roundtable had surfaced a strong set of themes for the upcoming show: BIM and digital twins, AI and data platforms, industrialised construction, startup innovation, governance-led technology adoption, robotics, sustainable materials, and integrated project delivery.

More importantly, the session established CTS 2026 as more than an exhibition. It is shaping up to be a serious industry platform where users, technology providers, researchers and policymakers can collectively define the future of construction.

As Padode noted in his closing remarks, the conversation will continue through further consultations and possibly webinars in the run-up to the show. If the roundtable is any indication, CTS 2026 will aim not merely to showcase technology, but to push the industry towards meaningful adoption at scale.

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Concrete

Human Factor in Grinding Optimisation

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Ponnusamy Sampathkumar, Consultant – Process Optimisation and Training, discusses the role of skilled operators as the decisive link between advanced additives, digital control and world-class mill performance.

The industry always tries to reduce the number of operators in the Centre Control Room. (CCR) Though the concept was succeeded to certain extent, still we need a skilled person in the CCR.
In an era where artificial intelligence (AI) grinding aids, performance enhancers, and digital optimisation tools are becoming increasingly sophisticated, it’s tempting to believe that chemistry alone can solve the challenges of mill efficiency. Yet plants that consistently outperform their peers share one common trait: highly skilled operators who understand the mill as a living system, not just a machine.
Additives can improve flowability, reduce agglomeration, and enhance separator efficiency, but they cannot replace the nuanced judgement that comes from experience. Grinding is a dynamic process influenced by raw material variability, moisture, liner wear, ball charge distribution, ventilation, and separator loading. No additive can fully compensate for poor control of these fundamentals.

Operators see what additives cannot
When I joined the cement industry in 1981, not much modernisation was available then. Mostly the equipment was run from the local panel. Once I was visiting the cement mills section. The cement mills were water sprayed over the shell to reduce the temperature to avoid the gypsum disintegration.
The operator stopped the feeding for one of the mills. When I asked the reason, he replied that mill was getting jammed, and he added that he could understand the mill condition by its sound. I also learned that and it was useful throughout my career. In another plant I saw the ‘Electronic Ear,’ which checked the sound of the mill and the signal was looped with feed control!
Whatever modernisation we achieve, it is from the human factor that the development starts.
Additives respond to conditions; operators interpret them.
A skilled operator can detect subtle shifts, like a change in mill sound, a slight variation in circulating load, or a drift in separator cut point. It’s long before instrumentation flags a problem. These micro-observations often prevent major efficiency losses.
Additives work best when the process is stable
I would like to share one real time incident. The mill was running on auto mode looped with the mill outlet bucket elevator kilowatt. (KW)There was a decrease in the KW, and the mill feed was increased by the auto control (PID). After a while, the operator stopped both the feed and the mill. He asked the local operator to check the airslide between mill outlet and the elevator. They found the airslide was jammed and no material flow to the elevator!
The operator deduced the abnormality by his experience by seeing the conditions and the rate of increase of the feed by the auto control.
It’s always the human factor that adds value to the optimisation.

Grinding aids are multipliers,
not magicians.
They deliver maximum benefit only when:
• Mill ventilation is correct
• Ball charge is balanced
• Feed moisture is controlled
• Separator speed and loading are improved
• Blaine targets are realistic
Without these fundamentals, even advanced additives may become costly investments. The operator is responsible for ensuring process stability, whether using a ball mill or a vertical mill. After ensuring the system is stable, the operator observes it briefly before transitioning to automatic control. If there is any anomaly in the system the operator at once takes control of the system, stabilises and bring back to auto control.

Skilled operators adapt in real time
It will be interesting to note that the operators who operate from local panel start to operate from DCS also. They have the experience and the ability to adapt the changes. Operator checks each parameter deeply. Any meagre change in the parameters is also visible to him.
Raw materials change. Weather changes. Wear patterns change.
A skilled operator adjusts:
• Feed rate
• Water injection
• Separator speed
• Grinding pressure (in VRMs)
• Mill load distribution.
These adjustments require intuition built from years of experience, something no additive can replicate.

Human insight prevents over reliance on additives
Plants sometimes increase additive dosage to mask deeper issues like:
• Poor clinker quality
• Inadequate drying capacity
• Incorrect ball gradation
• High residue due to worn separator internals.


A knowledgeable operator finds root causes instead of chasing temporary chemical fixes.
The real optimisation sweet spot is reached when:
• Operators understand how additives interact with their specific mill.
• Additive suppliers collaborate with plant teams.
• Process data is interpreted by humans who know the mill’s behaviour.
This constructive collaboration consistently delivers:
• Lower kWh/t
• Higher throughput
• Better product consistency
• Optimum standard deviation.

Advanced additives are powerful tools, but they are not substitutes for human ability. Grinding optimisation is ultimately a human driven discipline, where skilled operators make the difference between average performance and world class efficiency. Additives enhance the process but operators
control it.

About the author:
Ponnusamy Sampathkumar, Consultant – Process Optimisation and Training, is a seasoned cement process consultant with 43+ years of global experience in plant operations, process optimisation, refractory management, safety systems and training multicultural teams across international cement plants.

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